EP3197676B1 - Verfahren zur herstellung eines aus wässrigem harz hergestellten verbundteils und verbundteil aus solch einem verfahren - Google Patents

Verfahren zur herstellung eines aus wässrigem harz hergestellten verbundteils und verbundteil aus solch einem verfahren Download PDF

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Publication number
EP3197676B1
EP3197676B1 EP15729757.3A EP15729757A EP3197676B1 EP 3197676 B1 EP3197676 B1 EP 3197676B1 EP 15729757 A EP15729757 A EP 15729757A EP 3197676 B1 EP3197676 B1 EP 3197676B1
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EP
European Patent Office
Prior art keywords
mat
fibers
web
mats
spacer
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EP15729757.3A
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English (en)
French (fr)
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EP3197676A1 (de
Inventor
Steve JEUNESSE
Valérie Marcel
Moussa KHALFALLAH
Boussad ABBES
François VANFLETEREN
Frédéric Rousseau
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lineo NV
Universite de Reims Champagne Ardenne URCA
PSA Automobiles SA
Adler Pelzer France Grand Est SAS
Original Assignee
Lineo NV
Universite de Reims Champagne Ardenne URCA
Faurecia Automotive Industrie SAS
PSA Automobiles SA
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Publication of EP3197676A1 publication Critical patent/EP3197676A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/006—Degassing moulding material or draining off gas during moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/10—Moulds or cores; Details thereof or accessories therefor with incorporated venting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • B29D24/005—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled the structure having joined ribs, e.g. honeycomb
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/34—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts
    • E04C2/36—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels
    • E04C2/365—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure composed of two or more spaced sheet-like parts spaced apart by transversely-placed strip material, e.g. honeycomb panels by honeycomb structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2103/00—Use of resin-bonded materials as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels

Definitions

  • the present invention relates to a method of manufacturing a structural composite part, particularly for a motor vehicle, and the resulting composite structural part.
  • Such a method allows to obtain, in a single molding step or thermoforming, a panel formed of two mats, or composite skins, separated by a spacer.
  • the resin present in the skins also ensures the joining of the skins with the spacer.
  • the spacer is usually made of cardboard, in the form of a honeycomb structure. Excessive pressure during the compression step would cause it to crush, rendering the panel unusable. This is what happens when the skins consist of mats of entangled fibers produced by carding-lay-needling as described in WO2012 / 056202 .
  • thermosetting resin when the thermosetting resin is aqueous-based and / or generates water during its polymerization or crosslinking, this water in the form of steam may interfere with the joining of the skins with the spacer and / or cause local collapse of the spacer. The panel is then unusable.
  • crosslinking reaction requires a minimum water content, of the order of 5 to 10% by weight of resin, present before crosslinking, in order to allow the mobility of the molecules that react.
  • An "initial" lack of water leads to imperfect crosslinking, which results in poorly bonded fibers and / or skins poorly adhered to the retractor
  • the panel does not have the defects described above, the water that can not be removed during compression remains present in the product before demolding which limits the density of the skins (high porosity in the finished product) and therefore the mechanical performance of the panel.
  • the present invention aims to provide a simple method of manufacturing a structural composite part, to maintain optimal moisture of the resin without the water vapor generated by the heating disrupts the integrity of the room.
  • a second object of the invention is to provide a composite part comprising skins of high density, and therefore of low porosity, constituting true composites.
  • Another object of the invention is to facilitate impregnation and conditioning of the web.
  • the invention also relates to a structural composite part that can be obtained from a method as described above, said part comprising a first mat, a spacer and a second mat, the spacer being disposed between the first matte and the second mat, at least one of the first and second mats comprising a continuous web of fibers impregnated with a composition comprising a thermosetting resin, said web comprising a plurality of parallel fibers bonded together by the composition, said part comprising a first and a second layers respectively disposed in contact with the first and second mats, the side opposite the spacer, the first and the second layers being porous with water vapor and relatively less porous to the thermosetting resin.
  • the figure 1 is a sectional view of a structural composite part 10 of a motor vehicle.
  • the piece 10 is a structuring part of the motor vehicle, for example a panel, such as a trunk hide rear shelf, a false floor cockpit or trunk, or a sub-engine.
  • An axis 11 is considered substantially perpendicular to a mean plane of the structural part 10.
  • the structural composite part 10 comprises a first 12A and a second mat 12B, and a spacer 14, interposed between the two mats 12A, 12B.
  • the spacer 14 is preferably made of a light material, such as paper or cardboard.
  • the spacer 14 is made based on a cellular or honeycomb structure.
  • the spacer 14 has a plurality of walls 15 substantially parallel to the axis 11.
  • the walls 15 delimit central spaces 16 of closed contour, for example of polygonal shape, forming the cells.
  • the spacer 14 comprises opposite faces 18A, 18B formed by the ends of the walls 15 along the axis 11.
  • the faces 18A, 18B thus have a discontinuous surface.
  • Each mat 12A, 12B is fixed on a face 18A, 18B.
  • the density of the spacer 14 is preferably low, in particular less than 1500 g / m 2 and more preferably between 400 g / m 2 and 1200 g / m 2 .
  • At least one of the first 12A and second 12B mats comprises at least one continuous web 20 of fibers, said web 20 comprising a plurality of parallel fibers bonded together by a thermosetting resin 21.
  • the web 20 is called “unidirectional web” or “unidirectional web”, that is to say that the fibers of the web 20 are arranged parallel to each other in a longitudinal direction.
  • Such sails are described in particular in the document WO2013 / 068355 .
  • the fibers of the web 20 are long fibers, that is to say have a length greater than 20 centimeters, more preferably greater than 50 centimeters.
  • the length of the long fibers is for example between 50 and 80 centimeters.
  • the long fibers give the veil 20 interesting properties of mechanical strength, as described for example in the document WO2013 / 068355 .
  • the fibers of the web 20 are natural fibers.
  • all the fibers of the web 20 are made of natural long fibers.
  • a portion of the fibers of the web 20 is formed by artificial or synthetic fibers, separate from natural long fibers, or by a mixture of these fibers.
  • the natural long fibers are advantageously fibers extracted from plants, in particular flax fibers.
  • the natural long fibers are sisal, jute, hemp, kenaf fibers.
  • Artificial fibers are for example chosen from regenerated cellulose fibers, such as viscose.
  • the synthetic fibers are, for example, polyolefin fibers, especially chosen from polyethylene, polypropylene, polyester, polyamide and polyimide fibers, and mixtures thereof.
  • the synthetic fibers are bi-component fibers formed of a polymer and a copolymer, the polymer and its copolymer having different melting points.
  • the synthetic fibers are based on thermoplastic polymers, which allows, during a thermoforming step at the melting temperature of the polymer, to bind the natural fibers.
  • the mass proportion of long fibers of natural origin of the web 20 is greater than 50% of the total mass of the fibers of the web 20.
  • each of the first 12A and second 12B mats comprises a plurality of webs 20 as described above, these webs 20 being stacked on each other.
  • each of the mats 12A, 12B has between three and eight stacked sails.
  • the parallel fibers of each web 20 are arranged to form a non-zero angle, in particular a right angle, with the parallel fibers of each other adjacent web. Such an arrangement reinforces the corresponding mat 12A, 12B, depending on the orientation of the constraints of the finished part in situation.
  • the first 12A and second 12B mats have the same number of stacked webs 20, or alternatively different numbers of stacked webs 20.
  • the resin 21 is preferably a water-based resin, more preferably an acrylic resin.
  • This type of resin is of great interest in combination with natural fibers because its affinity with this type of fiber is excellent, for a moderate cost and environmental impact.
  • An example of a usable acrylic resin is marketed by BASF under the name Acrodur®.
  • the outer faces of the piece 10 are formed of a first 22A and a second 22B surface layers.
  • the first 22A and the second 22B surface layers are respectively in contact with the first 12A and the second 12B mats.
  • the first 22A and the second 22B surface layers are preferably formed of a nonwoven material. This is for example a carpet or a nonwoven of the spunbonded type .
  • each layer 22A, 22B is secured to the corresponding mat 12A, 12B by partial impregnation of resin 21.
  • the first 22A and the second 22B surface layers serve as exterior facing to the part 10. Another function of the layers 22A, 22B will be detailed below.
  • the first 22A and the second 22B surface layers have a controlled porosity. More precisely, the first 22A and the second 22B surface layers are porous with water vapor and non-porous with the thermosetting resin 21.
  • the porosity is defined in particular by the resistance to the passage of air (RPA), measured according to the ISO 9053.
  • RPA resistance to the passage of air
  • at least one of the first 22A and second 22B surface layers has an RPA of between 30 Ns / m 3 and 300 Ns / m 3 , more preferably between 50 Ns / m 3 and 200 Ns / m 3 .
  • Such a method firstly comprises the production of at least one continuous web 20 of fibers.
  • a veil is for example manufactured in the manner described in document WO2013 / 068355 according to the following steps: bringing in parallel a plurality of disjointed fiber ribbons; dispersion of adjacent ribbons across a field of tips for forming a parallel band of fibers; tensioning and stretching the web in the field of points parallel to a scroll axis.
  • this formation of the web 20 is followed by the addition of a binder capable of ensuring the transverse cohesion of the fibers to each other.
  • This binder is for example water spray, able to dissolve the natural cements of the fibers, which then stick the fibers together while drying. This optional step is described in the document WO2013 / 068355 .
  • the cohesion of the fibers between them is directly ensured by the following step of the process, which implements the impregnation of the veil with a composition comprising the thermosetting resin 21.
  • the composition further comprises at least one adjuvant, such as a surfactant and / or a thickener.
  • a surfactant such as a surfactant and / or a thickener.
  • a thickener such as BASF's Acrodur® product line.
  • the impregnation step can be carried out in various known ways, such as vaporization of the composition on the web or contact coating.
  • the impregnation stage is preferably followed by drying, in order to remove a part of the water contained in the composition. This drying allows the resin to ensure a certain cohesion of the fibers between them, without crosslinking. The transient bond between the fibers is relatively weak and is intended only to allow the handling of the web 20.
  • the drying is preferably carried out until the percentage of water present in the haze is less than 5%, preferably less than 3%. In this percentage of water, it does not take into account the water present inside the fibers themselves, which can vary according to their nature. In this case we talk about total drying and dry veil.
  • the web 20 impregnated with resin 21 can thus be packaged for storage, for example in the form of a roll interposed with an intermediate sheet as described in document WO2013 / 068355 .
  • the veil 20 thus conditioned can be transported to a molding or thermoforming place, and possibly stored again.
  • the advantage of having a dry veil lies in the possibility of using for packaging a plain paper. Indeed, when water remains too much - above 5% - with the resin in the veil, it can remain tacky or sticky and adhere to the interlayer sheet which causes time loss during the preparation of mats 12A, 12B. It is then necessary, to avoid this drawback, to use interleaves of the paper or silicone film type. These interleavers are not reusable they are to be considered as consumables that can significantly impact the price of the veil.
  • thermoforming steps are carried out at the impregnation line of the web 20 by the composition comprising the thermosetting resin 21.
  • the figure 2 represents a device 30 for manufacturing the composite part 10 according to one embodiment of the invention.
  • the device 30, in this case a heating mold comprises a first portion 32A and a second portion 32B.
  • the first and second portions 32A, 32B form an inner surface 34 complementary to the desired shape of the part 10.
  • the heating mold 30 comprises means for evacuating water vapor generated inside the mold.
  • perforations 36 pass through a thickness of at least one, and preferably both parts 32A, 32B. More specifically, the perforations 36 open at the same time on the internal surfaces 34 of the parts 32A, 32B and on the outside of the mold 30.
  • the mold 30 further comprises means (not shown) for heating the portions 32A, 32B and compressing said portions 32A, 32B against each other.
  • the molding or thermoforming of the composite part 10 comprises the arrangement of the first 22A and second 22B surface layers in contact with the inner surfaces 34, respectively of the first portion 32A and the second portion 32B.
  • Unidirectional webs impregnated with uncrosslinked resin 21, as described above, are then stacked over the first 22A and the second 22B surface layers to form respectively the first 12A and the second 12B matts.
  • the webs 20 of the same mat 12A, 12B are preferably stacked so as to cross the directions of the fibers of two adjacent webs 20.
  • one or more other types of materials are interposed with the unidirectional web (s) to form the mats 12A, 12B.
  • the webs 20 impregnated with uncrosslinked resin 21 are sprayed with water, for example by spraying, in order to restore a moisture content that is suitable for the crosslinking reaction.
  • water for example by spraying
  • the moisture content considered as suitable for the crosslinking reaction is at least 5%.
  • a higher level for example greater than 10%, does not generally hinder the crosslinking.
  • the amount of water brought in during this spraying step does not need to be controlled accurately, which greatly facilitates the implementation of this step.
  • the two parts 32A, 32B of the mold are arranged vis-à-vis one another, the spacer 14 being placed between the first 12A and the second 12B mats as shown in figure 2 .
  • the method then comprises a step of compressing and heating the stack by the mold 30, as shown in FIG. figure 3 .
  • Compression is effected by bringing the parts 32A, 32B of the mold 30 closer to one another as shown by the white arrows.
  • the heating is carried out at a temperature and for a time permitting the crosslinking of the thermosetting resin 21.
  • the heating temperature is for example between 150 ° C and 250 ° C for an acrylic resin.
  • the resin 21 By crosslinking, the resin 21 firmly binds the fibers of each web 20 between them, and the different webs 20 between them, as well as the mats 12A, 12B to the spacer 14.
  • the compression and heating step leads the resin 21 to occupy the entire space between the fibers of the webs 20 and any other materials forming the mats 12A, 12B.
  • the mats 12A, 12B formed of unidirectional sails 20 are dense and thin. Compression can be performed at a relatively low pressure, which avoids deterioration of the spacer 14, in particular its honeycomb structure.
  • the heating leads to the evaporation of the water impregnating the sails 20.
  • the crosslinking of certain resins, such as acrylic resins generates water.
  • the water vapor 37 thus generated passes through the surface layers 22A, 22B and is removed from the mold 30 by the perforations 36. Resin molecules 21, much larger in size than the water molecules, are retained by the surface layers 22A, 22B. Said surface layers 22A, 22B therefore have a function of filtering the water vapor during the compression and heating step.
  • the resin 21 reacts with surface fibers of the surface layers 22A, 22B and / or impregnates said surface fibers.
  • the first 22A and the second 22B surface layers are thus fixed, respectively on the first 12A and on the second 12B mats.
  • the air gap 38 represents the minimum distance between the spacer 14 and the internal surface 34, i.e. the distance at the end of the compression step.
  • the air gap 38 is chosen according to the desired density for the composite skins formed by the mats 12A, 12B after crosslinking of the resin 21. If the gap 38 is insufficient, the compression is too great and the resin 21 risk of crossing the surface layers 22A, 22B and sticking said layers 22A, 22B to the inner surface 34 of the mold 30. On the contrary, if the gap 38 is too large, the compression is insufficient and the composite is not quite densified.
  • Another parameter related to the choice of the gap 38 is the amount of resin solids 21 in the mats 12A, 12B.
  • the desired density for the composite forming the mats 12A, 12B is 1,000 g / m 2 .
  • the total weight of the fibers forming the sails 20 stacked to form each mat 12A, 12B, as at figure 2 is, for example, 400 g / m 2 .
  • the amount of resin solids 21 of each mat 12A, 12B must therefore be 600 g / m 2 .
  • the desired density for the composites formed by the mats 12A, 12B after crosslinking is, for example, equal to 1.
  • the air gap 38 must therefore correspond to a weight of 1000 g / m 2 for a density of 1, ie 1 mm, plus the thickness 40 of the surface layer 22A or 22B.
  • the thickness 40 is 0.2 mm for a surface layer of 120 g / m 2 .
  • the method described above allows evacuation of the steam generated during the compression and heating step, without the resin 21 protruding from the mold 30 by the perforations 36 and / or blocking the perforations 36.
  • the choice of air gap 38 depends solely on the amount of resin solids in the webs before crosslinking, and not on the total weight of resin.
  • the amount of water in the resin before crosslinking can therefore be modified at will.
  • water may be sprayed on the webs 20 before stacking in the mold 30, as described above, in order to guarantee a moisture content favorable to the crosslinking reaction.
  • this method allows the use of dry sails, which avoids the use of expensive spacers and precise control of the moisture content in the web.
  • the spacer 14 prior to its insertion into the mold between the mats 12A and 12B, is coated on its two faces 18A, 18B with an adhesive which will react under the effect of the temperature of the mold.
  • This variant ensures better bonding between the mats 12A, 12B and the spacer 14, because the amount of glue is better controlled than in the case where the bonding is only provided by the resin 21 already present in the sails.
  • the molding device 30 described above also makes it possible to evacuate the water possibly generated / released by the glue during the heating step.

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Claims (11)

  1. Verfahren zum Herstellen eines strukturellen Verbundteils (10), wobei das Verfahren die folgenden Schritte aufweist:
    - einen Schritt des Stapelns einer ersten Matte (12A), eines Abstandshalters (14) und einer zweiten Matte (12B) in einer heizenden Form (30), wobei der Abstandshalter zwischen der ersten und der zweiten Matte angeordnet ist, wobei mindestens eine von der ersten und der zweiten Matte ein durchgehendes Faservlies (20) aufweist, das mit einer Zusammensetzung imprägniert ist, die ein duroplastisches Harz (21) aufweist, wobei das Vlies eine Mehrzahl von parallelen Fasern aufweist, die durch die Zusammensetzung miteinander verbunden sind,
    - einen Schritt des Komprimierens und des Erhitzens des Stapels durch die heizende Form, wobei das Erhitzen bei einer Temperatur und während einer Dauer erfolgt, die Polymerisieren oder Retikulieren des duroplastischen Harzes ermöglichen,
    wobei das Verfahren dadurch gekennzeichnet ist, dass:
    - der Schritt des Stapelns das Anordnen einer ersten (22A) und einer zweiten (22B) Filterschicht in der heizenden Form aufweist, wobei die erste und die zweite Filterschicht jeweils in Kontakt mit der ersten (12A) und der zweiten (12B) Matte auf der zum Abstandshalter (14) entgegengesetzten Seite angeordnet sind, wobei die erste und die zweite Filterschicht gegenüber Wasserdampf porös und gegenüber dem duroplastischen Harz relativ weniger porös sind, und
    - die heizende Form Mittel (36) zum Ableiten von Wasserdampf (37) aufweist, der während des Schrittes des Komprimierens und des Erhitzens gebildet wird.
  2. Verfahren gemäß Anspruch 1, wobei die Zusammensetzung, die das duroplastische Harz (21) aufweist, eine wässrige Lösung ist, und/oder das duroplastische Harz während seiner Polymerisierung oder Retikulation Wasser erzeugt.
  3. Verfahren gemäß Anspruch 1 oder 2, wobei mindestens eine von der ersten (22A) und der zweiten (22B) Filterschicht einen Widerstand gegenüber dem Hindurchströmen von Luft von zwischen 30 N.s/m3 und 300 N.s/m3, vorzugsweise von zwischen 50 N.s/m3 und 200 N.s/m3 hat.
  4. Verfahren gemäß einem der vorhergehenden Ansprüche, aufweisend im Vorfeld einen Schritt des Besprengens der ersten Matte (12A) und/oder der zweiten Matte (12B) mit Wasser.
  5. Verfahren gemäß einem der vorhergehenden Ansprüche, wobei der Schritt des Komprimierens und des Erhitzens zum Fixieren der ersten (22A) und der zweiten (22B) Filterschicht auf der ersten (12A) bzw. auf der zweiten (12B) Matte führt.
  6. Verfahren gemäß einem der vorhergehenden Ansprüche, aufweisend im Vorfeld das Herstellen einer Matte (12A, 12B), wobei das Herstellen die folgenden Schritte aufweist:
    - einen Schritt des Bereitstellens eines durchgehenden Vlieses (20) von Fasern, die parallel zueinander sind,
    - einen Schritt des Imprägnierens des Vlieses mit einer Zusammensetzung, die ein duroplastisches Harz (21) aufweist, und
    - einen Schritt des Trocknens des Vlieses.
  7. Verfahren gemäß Anspruch 6, wobei das Bereitstellen des durchgehenden Vlieses (20) die folgenden Schritte aufweist:
    - einen Schritt des parallelen Zuführens einer Mehrzahl von getrennten Faserbändern,
    - einen Schritt des Verteilens der benachbarten Bänder über ein Feld von Spitzen, um ein Band von parallelen Fasern auszubilden,
    - einen Schritt des unter-Spannung-Setzens und des Streckens des Bandes im Feld von Spitzen parallel zu einer Laufachse.
  8. Verfahren gemäß einem der vorhergehenden Ansprüche, wobei der Schritt des Stapelns der ersten (12A) und/oder der zweiten (12B) Matte das Stapeln einer Mehrzahl von durchgehenden Vliesen (20) aus parallelen Fasern in der heizenden Form (30) aufweist.
  9. Verfahren gemäß Anspruch 8, wobei die parallelen Fasern jedes Vlieses (20) angeordnet sind, um mit den parallelen Fasern jedes anderen benachbarten Vlieses einen Winkel von ungleich Null, vorzugsweise einen rechten Winkel auszubilden.
  10. Verfahren gemäß irgendeinem der vorhergehenden Ansprüche, welches vor dem Schritt des Stapelns die folgenden Schritte aufweist:
    - Definieren einer gewünschten flächenbezogenen Masse für die erste Matte (12A) und für die zweite Matte (12B) nach dem Imprägnieren mit der Zusammensetzung, die das Harz enthält,
    - Berechnen eines Luftspaltes zwischen dem Abstandshalter und jeder Wand der Form auf der Grundlage der flächenbezogenen Masse jeder Matte (12A, 12B), der Dicke jeder Filterschicht (22A, 22B) und der Trockensubstanz des Harzes ohne Berücksichtigung des Wassergehalts des Harzes.
  11. Strukturelles Verbundteil (10), das geeignet ist, aus einem Verfahren gemäß einem der vorhergehenden Ansprüche hervorzugehen, wobei das Teil eine erste Matte (12A), einen Abstandshalter (14) und eine zweite Matte (12B) aufweist, wobei der Abstandshalter (14) zwischen der ersten Matte (12A) und der zweiten Matte (12B) angeordnet ist, mindestens eine von der ersten und der zweiten Matte ein durchgehendes Faservlies (20) aufweist, das mit einer Zusammensetzung imprägniert ist, die ein duroplastisches Harz (21) aufweist, wobei das Vlies eine Mehrzahl von parallelen Fasern aufweist, die durch die Zusammensetzung miteinander verbunden sind,
    dadurch gekennzeichnet, dass es eine erste (22A) und eine zweite (22B) Schicht aufweist, die jeweils in Kontakt mit der ersten (12A) und der zweiten (12B) Matte auf der Seite entgegengesetzt zum Abstandshalter (14) angeordnet sind, wobei die erste und die zweite Schicht gegenüber Wasserdampf porös sind und gegenüber dem duroplastischen Harz relativ weniger porös sind.
EP15729757.3A 2014-09-24 2015-04-29 Verfahren zur herstellung eines aus wässrigem harz hergestellten verbundteils und verbundteil aus solch einem verfahren Active EP3197676B1 (de)

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FR1459031A FR3026045B1 (fr) 2014-09-24 2014-09-24 Procede de fabrication d'une piece composite a base de resine aqueuse et piece composite issue d'un tel procede
PCT/EP2015/059420 WO2016045802A1 (fr) 2014-09-24 2015-04-29 Procédé de fabrication d'une pièce composite à base de résine aqueuse et pièce composite issue d'un tel procédé

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GB9101395D0 (en) * 1991-01-22 1991-03-06 Short Brothers Plc Structural cellular component
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US5333357A (en) * 1993-06-04 1994-08-02 Duncan Richard N Carding machine having a fine-fiber brush
DE10033322B4 (de) * 2000-07-03 2005-08-04 HP-chemie Pelzer Ltd. Industrial Estate Verfahren zur Herstellung von Verbundelementen und Verbundelement
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CN101585287B (zh) * 2009-06-08 2013-01-30 何庭佳 玻璃墙纸复合板的生产方法
FR2982283B1 (fr) 2011-11-07 2015-01-16 Faurecia Automotive Ind Procede de fabrication d'un voile continu de fibres comprenant des fibres longues naturelles, installation et voile associes
CN103381315A (zh) * 2012-05-05 2013-11-06 辽宁天泽产业集团纺织有限公司 一种无纺过滤布的制造方法
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WO2016045802A1 (fr) 2016-03-31
FR3026045A1 (fr) 2016-03-25
LT3197676T (lt) 2018-12-10
FR3026045B1 (fr) 2016-12-09

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